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Manuel d’utilisation Lincoln Electric POWER MIG 255 SVM144-B

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  • Lincoln Electric POWER MIG 255 SVM144-B - page 1

    PO WER MIG 255 SVM144-B July , 2006 Safety Depends on Y ou Lincoln arc welding and cutting equipment is designed and built with safety in mind. However , your overall safety can be increased by pr oper installation . . . and thoughtful operation on your part. DO NOT INST ALL, OPERA TE OR REP AIR THIS EQUIPMENT WITHOUT READ- ING THIS MANUAL AND THE ...

  • Lincoln Electric POWER MIG 255 SVM144-B - page 2

    Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC i SAFETY i LN-15 FOR ENGINE powered equipment. 1.a. T urn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running. ____________________________________________________ 1.b. Operate engines in open, well-ventil ...

  • Lincoln Electric POWER MIG 255 SVM144-B - page 3

    Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ii SAFETY ii LN-15 ARC RA YS can burn. 4.a. Use a shield with the proper filter and cover plates to protect your eyes from sparks and the rays of the arc when welding or observing open arc welding. Headshield and filter lens should conform to ANSI Z87. I standards. ...

  • Lincoln Electric POWER MIG 255 SVM144-B - page 4

    POWER MIG 255 SAFETY iii iii Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC FOR ELECTRICALL Y powered equipment. 8.a. T urn off input power using the disconnect switch at the fuse box before working on the equipment. 8.b. Install equipment in accordance with the U.S. National Electrical Code, all local codes and ...

  • Lincoln Electric POWER MIG 255 SVM144-B - page 5

    POWER MIG 255 SAFETY iv iv Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC PRÉCAUTIONS DE SÛRETÉ Pour votre propre protection lire et observer toutes les instructions et les précautions de sûreté specifiques qui parraissent dans ce manuel aussi bien que les précautions de sûreté générales suiv- antes: ...

  • Lincoln Electric POWER MIG 255 SVM144-B - page 6

    POWER MIG 255 v v MASTER T ABLE OF CONTENTS FOR ALL SECTIONS Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i-iv Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section A Operation . . . . . . . . . . . . . . ...

  • Lincoln Electric POWER MIG 255 SVM144-B - page 7

    Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC X Section A-1 Section A-1 T ABLE OF CONTENTS - INST ALLA TION SECTION - Installation ..............................................................................................................Secti on A T echnical Specifications .................................. ...

  • Lincoln Electric POWER MIG 255 SVM144-B - page 8

    POWER MIG 255 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC A-2 INST ALLA TION A-2 75°C Copper Wire 75°C Copper Wire in Conduit in Conduit Input Ampere A WG (IEC) Sizes A WG (IEC) Sizes Input V oltage/ Fuse or Breaker Rati ...

  • Lincoln Electric POWER MIG 255 SVM144-B - page 9

    POWER MIG 255 INST ALLA TION A-3 A-3 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC INPUT POWER, GROUNDING AND CONNECTION DIAGRAMS ------------------------------------------------------------------------ 1. Before starting th ...

  • Lincoln Electric POWER MIG 255 SVM144-B - page 10

    POWER MIG 255 INST ALLA TION A-4 A-4 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC 4. Using the instructions in Figure A.3 , have a qual- ified electrician connect the receptacle or cable to the input power lines and the sys ...

  • Lincoln Electric POWER MIG 255 SVM144-B - page 11

    POWER MIG 255 INST ALLA TION A-5 A-5 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC FIGURE A.3 — RECEPT ACLE DIAGRAM. CONNECT TO A SYSTEM GROUNDING WIRE. SEE THE UNITED ST A TES NA TIONAL ELECTRICAL CODE AND/OR LOCAL CODES ...

  • Lincoln Electric POWER MIG 255 SVM144-B - page 12

    POWER MIG 255 INST ALLA TION A-6 A-6 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC GUN AND CABLE INST ALLA TION The Magnum 250L gun and cable provided with the POWER MIG 255 is factory installed with a liner for 0.035-0.045 ...

  • Lincoln Electric POWER MIG 255 SVM144-B - page 13

    Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC POWER MIG 255 Section B-1 Section B-1 T ABLE OF CONTENTS - OPERA TION SECTION - Operation ................................................................................................................Sectio n B Product Description.................................. ...

  • Lincoln Electric POWER MIG 255 SVM144-B - page 14

    POWER MIG 255 OPERA TION B-2 B-2 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Read entire Operation section before operating the POWER MIG 255. ELECTRIC SHOCK can kill. • Do not touch electrically live parts or electrode ...

  • Lincoln Electric POWER MIG 255 SVM144-B - page 15

    POWER MIG 255 OPERA TION B-3 B-3 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC PRODUCT DESCRIPTION The POWER MIG™ 255 is a complete semiautomatic constant voltage DC arc welding machine built to meet NEMA specifications. I ...

  • Lincoln Electric POWER MIG 255 SVM144-B - page 16

    POWER MIG 255 OPERA TION B-4 B-4 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC DESCRIPTION OF CONTROLS Power ON/OFF Switch — Place the lever in the “ON” position to energize the POWER MIG 255. When the power is on, the ...

  • Lincoln Electric POWER MIG 255 SVM144-B - page 17

    POWER MIG 255 OPERA TION B-5 B-5 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC PROCEDURE FOR CHANGING DRIVE AND IDLE ROLL SETS 1. T urn off the power source. 2. Release the pressure on the idle roll by swinging the adjustabl ...

  • Lincoln Electric POWER MIG 255 SVM144-B - page 18

    POWER MIG 255 OPERA TION B-6 B-6 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TO ST ART THE WELDER T urn the Power Switch switch to ON. This lights the red LED display lights. With the desired voltage and wire speed selecte ...

  • Lincoln Electric POWER MIG 255 SVM144-B - page 19

    POWER MIG 255 OPERA TION B-7 B-7 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC NOTE: Arc starting characteristics may be effected when using the fast run-in mode since optimum start- ing processes are being overridden. On th ...

  • Lincoln Electric POWER MIG 255 SVM144-B - page 20

    POWER MIG 255 OPERA TION B-8 B-8 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC 5. Use only clean, rust-free electrode. The Lincoln electrodes have proper surface lubrication. 6. Replace contact tip when the arc starts to bec ...

  • Lincoln Electric POWER MIG 255 SVM144-B - page 21

    Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC POWER MIG 255 Section C-1 Section C-1 T ABLE OF CONTENTS - ACCESSORIES SECTION - Accessories ............................................................................................................Section C Drive Roll Kits ....................................... ...

  • Lincoln Electric POWER MIG 255 SVM144-B - page 22

    POWER MIG 255 ACCESSORIES C-2 C-2 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC DRIVE ROLL KITS Refer to T able C.1 for various drive roll kits that are available for the POWER MIG. All items in Bold are supplied standard wi ...

  • Lincoln Electric POWER MIG 255 SVM144-B - page 23

    POWER MIG 255 ACCESSORIES C-3 C-3 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC 3. Using a screwdriver , remove the two screws securing the lower cover panel to the front of the machine. Remove the lower cover panel. 4. Atta ...

  • Lincoln Electric POWER MIG 255 SVM144-B - page 24

    POWER MIG 255 ACCESSORIES C-4 C-4 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC SPOOL GUN ADAPTER KIT Remove all input power to the POWER MIG 255 before proceeding. ----------------------------------------------------------- ...

  • Lincoln Electric POWER MIG 255 SVM144-B - page 25

    Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC POWER MIG 255 Section D-1 Section D-1 T ABLE OF CONTENTS - MAINTENANCE SECTION - Maintenance ...........................................................................................................Section D Safety Precautions ..................................... ...

  • Lincoln Electric POWER MIG 255 SVM144-B - page 26

    POWER MIG 255 MAINTENANCE D-2 D-2 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC SAFETY PRECAUTIONS • Have a qualified electrician do the maintenance and troubleshooting work. • Disconnect the input power off using the di ...

  • Lincoln Electric POWER MIG 255 SVM144-B - page 27

    POWER MIG 255 MAINTENANCE D-3 D-3 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC FIGURE D.1 — COMPONENT LOCA TIONS. CONTROL PC BOARD POWER ENHANCEMENT CHOKE OUTPUT CHOKE MAIN TRANSFORMER SCR RECTIFIER BRIDGE CAPACITOR BANK ...

  • Lincoln Electric POWER MIG 255 SVM144-B - page 28

    POWER MIG 255 MAINTENANCE D-4 D-4 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC CONT ACT TIP AND GAS NOZZLE INST ALLA TION 1. Choose the correct size contact tip for the elec- trode being used (wire size is stenciled on the ...

  • Lincoln Electric POWER MIG 255 SVM144-B - page 29

    POWER MIG 255 MAINTENANCE D-5 D-5 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC GUN HANDLE DISASSEMBL Y The internal parts of the gun handle may be inspected or serviced if necessary . The gun handle consists of two halves t ...

  • Lincoln Electric POWER MIG 255 SVM144-B - page 30

    POWER MIG 255 MAINTENANCE D-6 D-6 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ACCESSORIES AND EXPENDABLE REPLACEMENT P ARTS FOR MAGNUM 250L GUN AND CABLE ASSEMBLIES * Included with Power MIG 255. ** Requires S19418-1 Gas D ...

  • Lincoln Electric POWER MIG 255 SVM144-B - page 31

    Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC POWER MIG 255 Section E-1 Section E-1 Theory of Operation ...............................................................................................Section E Input Line V oltage and Main T ransformer.............................................................. ...

  • Lincoln Electric POWER MIG 255 SVM144-B - page 32

    POWER MIG 255 THEOR Y OF OPERA TION E-2 E-2 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC INPUT LINE VOL T AGE AND MAIN TRANSFORMER The desired single phase input power is connected to the POWER MIG 255 through a line switch ...

  • Lincoln Electric POWER MIG 255 SVM144-B - page 33

    POWER MIG 255 THEOR Y OF OPERA TION E-3 E-3 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC OUTPUT RECTIFICA TION AND FEEDBACK CONTROL The AC output from the main transformer secondary weld winding is rectified and controlled ...

  • Lincoln Electric POWER MIG 255 SVM144-B - page 34

    POWER MIG 255 THEOR Y OF OPERA TION E-4 E-4 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC CONST ANT VOL T AGE OUTPUT The controlled DC output from the SCR rectifier assembly is supplied to the power factor enhancement choke ...

  • Lincoln Electric POWER MIG 255 SVM144-B - page 35

    POWER MIG 255 THEOR Y OF OPERA TION E-5 E-5 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC WIRE DRIVE MOT OR AND FEEDBACK The wire drive motor is controlled by the control board. A motor speed feedback signal is generated at ...

  • Lincoln Electric POWER MIG 255 SVM144-B - page 36

    POWER MIG 255 THEOR Y OF OPERA TION E-6 E-6 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC THERMAL AND OVERLOAD PROTECTION The POWER MIG 255 has built-in protective ther- mostats that respond to excessive temperatures. One is ...

  • Lincoln Electric POWER MIG 255 SVM144-B - page 37

    POWER MIG 255 THEOR Y OF OPERA TION E-7 E-7 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC SCR OPERA TION A silicon controlled rectifier (SCR) is a three terminal device used to control rather large currents to a load. An SCR ...

  • Lincoln Electric POWER MIG 255 SVM144-B - page 38

    POWER MIG 255 NOTES E-8 E-8 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ...

  • Lincoln Electric POWER MIG 255 SVM144-B - page 39

    Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC POWER MIG 255 Section F-1 Section F-1 T ABLE OF CONTENTS - TROUBLESHOOTING & REP AIR SECTION - Tr oubleshooting & Repair Section ........................................................................Section F How to Use T roubleshooting Guide ............. ...

  • Lincoln Electric POWER MIG 255 SVM144-B - page 40

    HOW TO USE TROUBLESHOOTING GUIDE Service and repair should be performed by only Lincoln Electric Factory T rained Personnel. Unauthorized repairs performed on this equipment may r esult in danger to the technician and machine operator and will invalidate your factory warranty . For your safety and to avoid Electrical Shock, please observe all safet ...

  • Lincoln Electric POWER MIG 255 SVM144-B - page 41

    POWER MIG 255 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-3 F-3 Sometimes machine failures appear to be due to PC board failures. These problems can sometimes be traced to poor electrical co ...

  • Lincoln Electric POWER MIG 255 SVM144-B - page 42

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-4 F-4 POWER MIG 255 CAUTION If for any reason you do not understand the test pr ocedures or are unable to perform the test/r epairs safely , con- ...

  • Lincoln Electric POWER MIG 255 SVM144-B - page 43

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-5 F-5 TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beginning of this manual. POWER MIG 255 CAUTION If for any reason you do not ...

  • Lincoln Electric POWER MIG 255 SVM144-B - page 44

    POWER MIG 255 TROUBLESHOOTING & REP AIR F-6 F-6 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC CAUTION If for any reason you do not understand the test pr ocedures or are unable to perform the test/r epairs safely , con- ...

  • Lincoln Electric POWER MIG 255 SVM144-B - page 45

    POWER MIG 255 TROUBLESHOOTING & REP AIR F-7 F-7 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC CAUTION If for any reason you do not understand the test pr ocedures or are unable to perform the test/r epairs safely , con- ...

  • Lincoln Electric POWER MIG 255 SVM144-B - page 46

    POWER MIG 255 TROUBLESHOOTING & REP AIR F-8 F-8 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC CAUTION If for any reason you do not understand the test pr ocedures or are unable to perform the test/r epairs safely , con- ...

  • Lincoln Electric POWER MIG 255 SVM144-B - page 47

    POWER MIG 255 TROUBLESHOOTING & REP AIR F-9 F-9 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC CAUTION If for any reason you do not understand the test pr ocedures or are unable to perform the test/r epairs safely , con- ...

  • Lincoln Electric POWER MIG 255 SVM144-B - page 48

    POWER MIG 255 TROUBLESHOOTING & REP AIR F-10 F-10 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC CAUTION If for any reason you do not understand the test pr ocedures or are unable to perform the test/r epairs safely , con ...

  • Lincoln Electric POWER MIG 255 SVM144-B - page 49

    Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty . For your safety and to avoid electrical shock, please observe all safety notes and pre- cautions detailed t ...

  • Lincoln Electric POWER MIG 255 SVM144-B - page 50

    POWER MIG 255 F-12 F-12 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR 4. Locate plug J5 and plug J6 on the G3521 control PC board, and J9 on the M19248 snubber PC board. See Figure F .1. NOTE: T ...

  • Lincoln Electric POWER MIG 255 SVM144-B - page 51

    POWER MIG 255 F-13 F-13 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR 11 .T urn the machine ON. 12. Make the following voltage tests at plug J5. a. T urn the machine OFF between each test. b. Ca ...

  • Lincoln Electric POWER MIG 255 SVM144-B - page 52

    POWER MIG 255 TROUBLESHOOTING AND REP AIR F-14 F-14 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC c. If any of the voltages tested are incorrect, check for loose or broken leads between the test points and the main transform ...

  • Lincoln Electric POWER MIG 255 SVM144-B - page 53

    POWER MIG 255 TROUBLESHOOTING & REP AIR F-15 F-15 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC RECTIFIER DIODE BRIDGE TEST Service and repair should only be performed by Lincoln Electric factory trained personnel. Unaut ...

  • Lincoln Electric POWER MIG 255 SVM144-B - page 54

    POWER MIG 255 TROUBLESHOOTING & REP AIR F-16 F-16 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Leads #208R, #209R, and #354 are connected to the rectifier diode bridge (D2). See Figure F .2. Lead #206 is connected at th ...

  • Lincoln Electric POWER MIG 255 SVM144-B - page 55

    POWER MIG 255 TROUBLESHOOTING & REP AIR F-17 F-17 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC 9. Make the following voltage test: a. T urn the machine OFF between each test. b. Carefully connect the meter probes to the ...

  • Lincoln Electric POWER MIG 255 SVM144-B - page 56

    POWER MIG 255 NOTES F-18 F-18 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ...

  • Lincoln Electric POWER MIG 255 SVM144-B - page 57

    POWER MIG 255 TROUBLESHOOTING & REP AIR F-19 F-19 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ST A TIC SCR RECTIFIER ASSEMBL Y TEST Service and repair should only be performed by Lincoln Electric factory trained person ...

  • Lincoln Electric POWER MIG 255 SVM144-B - page 58

    POWER MIG 255 TROUBLESHOOTING & REP AIR F-20 F-20 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC 4. V erify that the capacitors have completely discharged with a volt- ohmmeter . 5. Disconnect plugs J6 from the G3521 cont ...

  • Lincoln Electric POWER MIG 255 SVM144-B - page 59

    POWER MIG 255 TROUBLESHOOTING & REP AIR F-21 F-21 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC FIGURE F .5 — SCR 1 TEST POINTS. 9. T est for high or infinite resistance from the cathode to the anode of SCR 1 by revers ...

  • Lincoln Electric POWER MIG 255 SVM144-B - page 60

    POWER MIG 255 NOTES F-22 F-22 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ...

  • Lincoln Electric POWER MIG 255 SVM144-B - page 61

    POWER MIG 255 TROUBLESHOOTING & REP AIR F-23 F-23 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ACTIVE SCR RECTIFIER ASSEMBL Y TEST Service and repair should only be performed by Lincoln Electric factory trained personne ...

  • Lincoln Electric POWER MIG 255 SVM144-B - page 62

    POWER MIG 255 TROUBLESHOOTING & REP AIR F-24 F-24 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC 4. V erify that the capacitors have completely discharged with a volt- ohmmeter . 5. Disconnect plugs J6 from the G3521 cont ...

  • Lincoln Electric POWER MIG 255 SVM144-B - page 63

    POWER MIG 255 TROUBLESHOOTING & REP AIR F-25 F-25 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC 8. Use a commercial SCR tester or con- struct the tester circuit shown in Figure F .8. One 6-volt lantern battery can be use ...

  • Lincoln Electric POWER MIG 255 SVM144-B - page 64

    POWER MIG 255 TROUBLESHOOTING & REP AIR F-26 F-26 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC 15. Reconnect the tester leads. See Figure F .8. a. Connect tester lead (A) to the cathode. b. Connect tester lead (C) to th ...

  • Lincoln Electric POWER MIG 255 SVM144-B - page 65

    POWER MIG 255 TROUBLESHOOTING & REP AIR F-27 F-27 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC WIRE DRIVE MOTOR AND T ACHOMETER FEEDBACK TEST Service and repair should only be performed by Lincoln Electric factory train ...

  • Lincoln Electric POWER MIG 255 SVM144-B - page 66

    POWER MIG 255 TROUBLESHOOTING & REP AIR F-28 F-28 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC 3. Locate plug J1 on the G3521 control PC board. See Figure F .9. 4. Locate the following leads on plug J1: 5. Connect the m ...

  • Lincoln Electric POWER MIG 255 SVM144-B - page 67

    POWER MIG 255 TROUBLESHOOTING & REP AIR F-29 F-29 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC 2. Locate plug J1 on the G3521 control PC board. See Figure F .9. 3. Locate the following leads on Plug J1: 4. Connect main ...

  • Lincoln Electric POWER MIG 255 SVM144-B - page 68

    POWER MIG 255 TROUBLESHOOTING & REP AIR F-30 F-30 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC c. T urn the machine ON and pull the gun trigger to conduct the voltage test. 6. If the 1.5 to 3.5 VDC is present, the tacho ...

  • Lincoln Electric POWER MIG 255 SVM144-B - page 69

    POWER MIG 255 TROUBLESHOOTING & REP AIR F-31 F-31 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC 0 VOLTS 20.0 V 2.5 ms This is a typical DC output voltage waveform generated from a properly operating machine. Note that ea ...

  • Lincoln Electric POWER MIG 255 SVM144-B - page 70

    POWER MIG 255 TROUBLESHOOTING & REP AIR F-32 F-32 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC 0 VOLTS 20.0 V 5 ms MACHINE LOADED TO 250 AMPS A T 26 VDC TYPICAL OUTPUT VOL T AGE W A VEFORM - MACHINE LOADED This is a typ ...

  • Lincoln Electric POWER MIG 255 SVM144-B - page 71

    POWER MIG 255 TROUBLESHOOTING & REP AIR F-33 F-33 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC 0 VOLTS 20.0 V 5 ms MACHINE LOADED TO 220 AMPS A T 22 VDC ABNORMAL OUTPUT VOL T AGE W A VEFORM - MACHINE LOADED ONE OUTPUT S ...

  • Lincoln Electric POWER MIG 255 SVM144-B - page 72

    POWER MIG 255 TROUBLESHOOTING & REP AIR F-34 F-34 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC 0 VOLTS 20.0 V 5 ms ABNORMAL OPEN CIRCUIT VOL T AGE OUTPUT CAP ACIT OR BANK NOT FUNCTIONING This is NOT the typical DC outpu ...

  • Lincoln Electric POWER MIG 255 SVM144-B - page 73

    POWER MIG 255 TROUBLESHOOTING & REP AIR F-35 F-35 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC 0 VOLTS 2.00 V 5 ms TYPICAL SCR GA TE VOL T AGE W A VEFORM This is a typical SCR gate pulse voltage waveform. The machine wa ...

  • Lincoln Electric POWER MIG 255 SVM144-B - page 74

    POWER MIG 255 NOTES F-36 F-36 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ...

  • Lincoln Electric POWER MIG 255 SVM144-B - page 75

    POWER MIG 255 F-37 F-37 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING AND REP AIR Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on t ...

  • Lincoln Electric POWER MIG 255 SVM144-B - page 76

    POWER MIG 255 F-38 F-38 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING AND REP AIR CONTROL PC BOARD REMOV AL AND REPLACEMENT PROCEDURE (Continued) REMOV AL AND REPLACEMENT PROCEDURE 1. Disconnect main input po ...

  • Lincoln Electric POWER MIG 255 SVM144-B - page 77

    POWER MIG 255 F-39 F-39 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING AND REP AIR CONTROL PC BOARD REMOV AL AND REPLACEMENT PROCEDURE (Continued) 7. When re-installing the control PC board carefully secure bo ...

  • Lincoln Electric POWER MIG 255 SVM144-B - page 78

    POWER MIG 255 NOTES F-40 F-40 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ...

  • Lincoln Electric POWER MIG 255 SVM144-B - page 79

    POWER MIG 255 TROUBLESHOOTING & REP AIR F-41 F-41 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on ...

  • Lincoln Electric POWER MIG 255 SVM144-B - page 80

    POWER MIG 255 TROUBLESHOOTING & REP AIR F-42 F-42 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC 6. Disconnect the wire connectors J13 and J12 to the motor/gearbox assem- bly . See Wiring Diagram. 7. Use a 3/4 in. wrench ...

  • Lincoln Electric POWER MIG 255 SVM144-B - page 81

    POWER MIG 255 TROUBLESHOOTING & REP AIR F-43 F-43 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC 15. Grasp the motor/gearbox assembly and wiggle the motor/gearbox assembly gently back and forth until it separates from the ...

  • Lincoln Electric POWER MIG 255 SVM144-B - page 82

    POWER MIG 255 NOTES F-44 F-44 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ...

  • Lincoln Electric POWER MIG 255 SVM144-B - page 83

    POWER MIG 255 TROUBLESHOOTING & REP AIR F-45 F-45 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on ...

  • Lincoln Electric POWER MIG 255 SVM144-B - page 84

    POWER MIG 255 TROUBLESHOOTING & REP AIR F-46 F-46 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC 3. Disconnect lead #204 and heavy alu- minum choke lead from the middle heat sink with a 1/2 in. socket wrench and 1/2 in. o ...

  • Lincoln Electric POWER MIG 255 SVM144-B - page 85

    POWER MIG 255 TROUBLESHOOTING & REP AIR F-47 F-47 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC 8. Clear the leads and carefully remove the SCR rectifier assembly . NOTE: When installing the SCR rectifier assembly , appl ...

  • Lincoln Electric POWER MIG 255 SVM144-B - page 86

    POWER MIG 255 NOTES F-48 F-48 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ...

  • Lincoln Electric POWER MIG 255 SVM144-B - page 87

    POWER MIG 255 TROUBLESHOOTING & REP AIR F-49 F-49 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC The liquid electrolite in the capacitors is toxic. Do not touch the capacitors with any part of your body . ---------------- ...

  • Lincoln Electric POWER MIG 255 SVM144-B - page 88

    POWER MIG 255 TROUBLESHOOTING & REP AIR F-50 F-50 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC tive capacitor bank buss bar using a 1/2 in. open end wrench. 6. Remove the choke lead and lead 204B from the positive capac ...

  • Lincoln Electric POWER MIG 255 SVM144-B - page 89

    POWER MIG 255 TROUBLESHOOTING & REP AIR F-51 F-51 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on ...

  • Lincoln Electric POWER MIG 255 SVM144-B - page 90

    POWER MIG 255 TROUBLESHOOTING & REP AIR F-52 F-52 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC 6. Remove the two transformer secondary leads X2 and X3 (braided copper strap) from the negative capacitor bank buss bar usi ...

  • Lincoln Electric POWER MIG 255 SVM144-B - page 91

    POWER MIG 255 TROUBLESHOOTING & REP AIR F-53 F-53 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC 11 . Unplug and label leads X5, X6, X7, X8, and X9. These leads have connectors near the trans- former which can be disconne ...

  • Lincoln Electric POWER MIG 255 SVM144-B - page 92

    POWER MIG 255 NOTES F-54 F-54 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ...

  • Lincoln Electric POWER MIG 255 SVM144-B - page 93

    POWER MIG 255 TROUBLESHOOTING & REP AIR F-55 F-55 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on ...

  • Lincoln Electric POWER MIG 255 SVM144-B - page 94

    POWER MIG 255 TROUBLESHOOTING & REP AIR F-56 F-56 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC a. Loosen and remove the two nuts and lock washers from the motor mounting bracket using a 1 1/32 in. open end wrench. b. Wh ...

  • Lincoln Electric POWER MIG 255 SVM144-B - page 95

    POWER MIG 255 TROUBLESHOOTING AND REP AIR F-57 F-57 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC INPUT IDLE AMPS AND W A TTS WIRE SPEED RANGE OPEN CIRCUIT VOL T AGE RETEST AFTER REP AIR Maximum Idle W atts Maximum Idle Amps ...

  • Lincoln Electric POWER MIG 255 SVM144-B - page 96

    POWER MIG 255 NOTES F-58 F-58 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ...

  • Lincoln Electric POWER MIG 255 SVM144-B - page 97

    Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC POWER MIG 255 Section G-1 Section G-1 T ABLE OF CONTENTS - ELECTRICAL DIAGRAMS SECTION - Electrical Diagrams ...............................................................................................Section G Wiring Diagram - Entire Machine - Code 10563 - (L109 ...

  • Lincoln Electric POWER MIG 255 SVM144-B - page 98

    G-2 ELECTRICAL DIAGRAMS POWER MIG 255 WIRING DIAGRAM - ENTIRE MACHINE - CODE 10563 - (L10979) 392 325 515B 209S ** 204S 209R 209 209S W 254 256 551 254A 552 COLOR CODE: ELECTRICAL SYMBOLS PER E1537 GENERAL INFORMATION POWER MIG 255 (208/230V) 206B G2 4 5 J7 4 5 6 2 7 8 J11 GUN TRIGGER 2 325 4 3 4 J12 325 324 H4 H1 9 6 8 7 7 5 4 L1 7 2 1 5 6 265 263 ...

  • Lincoln Electric POWER MIG 255 SVM144-B - page 99

    G-3 ELECTRICAL DIAGRAMS POWER MIG 255 WIRING DIAGRAM - ENTIRE MACHINE - CODE 10583 - (L10980) G-3 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC 1 209 555 B W 515 254 262 207 P.M. 208S J9 B T A C H D1 ASBLY 2-23-2001A 11 1 28 ...

  • Lincoln Electric POWER MIG 255 SVM144-B - page 100

    G-4 ELECTRICAL DIAGRAMS POWER MIG 255 G-4 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC WIRING DIAGRAM - ENTIRE MACHINE - CODE 10986 - (L1 1980) NOTE: This diagram is for reference only . It may not be accurate for all machi ...

  • Lincoln Electric POWER MIG 255 SVM144-B - page 101

    G-5 ELECTRICAL DIAGRAMS POWER MIG 255 G-5 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC WIRING DIAGRAM - ENTIRE MACHINE - CODE 10990 - (L1 1979) NOTE: This diagram is for reference only . It may not be accurate for all machi ...

  • Lincoln Electric POWER MIG 255 SVM144-B - page 102

    G-6 ELECTRICAL DIAGRAMS POWER MIG 255 CONTROL PC BOARD SCHEMA TIC - (G3520-1D1) G-6 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC NOTE: Lincoln Electric assumes no responsibility for liablilities resulting from board level t ...

  • Lincoln Electric POWER MIG 255 SVM144-B - page 103

    G-7 ELECTRICAL DIAGRAMS POWER MIG 255 CONTROL PC BOARD ASSEMBL Y - (G3521-1) Ch’ge. Sht. No. 3521-1 XE-RW A POWER MIG 255 CONTROL P.C. BOARD ASSEMBLY C.S./ FULL 3521-1 12-18-98 G2803-1 THE LINCOLN ELECTRIC CO. CLEVELAND, OHIO U.S.A. EQUIP. TYPE SCALE DR DATE CHK REF. SUBJECT SUP’S’D’G SHT. NO. G G 5.80 .20 3-12-99 7-9-99H 7-28-2000J 10-5-20 ...

  • Lincoln Electric POWER MIG 255 SVM144-B - page 104

    G-8 ELECTRICAL DIAGRAMS POWER MIG 255 G-8 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC DISPLA Y PC BOARD SCHEMA TIC - (L10951) 500 475 R10 DISP2 2 1 4 9 5 10 7 6 8 3 LED3 X5 12 13 J10 4 DISP3 2 1 4 9 5 10 7 6 8 3 14 3 Rx Vd ...

  • Lincoln Electric POWER MIG 255 SVM144-B - page 105

    G-9 ELECTRICAL DIAGRAMS POWER MIG 255 G-9 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC DISPLA Y PC BOARD ASSEMBL Y - (L10952-1) 10952-1 Ch’ge. Sht. No. XA 3-12-99 A B POWER MIG 255 R.T. FULL 10952-1 5-20-98 THE LINCOLN EL ...

  • Lincoln Electric POWER MIG 255 SVM144-B - page 106

    G-10 ELECTRICAL DIAGRAMS POWER MIG 255 SNUBBER PC BOARD SCHEMA TIC - (S24374) 204S J1 1 J1 8 5W 10 R1 J1 6 J1 2 J1 3 J1 4 400V .68 C2 J1 5 J1 7 5W 10 R2 24374 209R SNUBBER BOARD NONE .022/50V MFD UNLESS OTHERWISE SPECIFIED) POWER SUPPLY SOURCE POINT POWERMIG 255 N.A. OF A COMPLETE ( CONTROLS HAVING A COMMON CODE NUMBER. NOTES : BOARD. SHOW THE EXAC ...

  • Lincoln Electric POWER MIG 255 SVM144-B - page 107

    G-11 ELECTRICAL DIAGRAMS POWER MIG 255 G-11 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC SNUBBER PC BOARD ASSEMBL Y - (M19248-1) 19248-1 Ch’ge. Sht. No. XB 3-12-99 B SP WELDERS SNUBBER P.C. BOARD AS’BLY R.T. FULL 19248- ...

  • Lincoln Electric POWER MIG 255 SVM144-B - page 108

    SVM ERROR REPORTING FORM We need to know if there are errors in our manuals. We also value any suggestions as to additional tests or procedures that would make this SVM a better tool for you. If you discover new or different “Problems or Symptoms” that are not covered in the three col- umn troubleshooting chart, please share this information wi ...

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Tous sont importants, mais les informations les plus importantes du point de vue de l'utilisation de l'appareil se trouvent dans le manuel d’utilisation Lincoln Electric POWER MIG 255 SVM144-B.

Un groupe de documents appelé manuels d’utilisation est également divisé en types plus spécifiques, tels que: Manuels d’installation Lincoln Electric POWER MIG 255 SVM144-B, manuels d’entretien, brefs manuels ou manuels de l’utilisateur Lincoln Electric POWER MIG 255 SVM144-B. Selon vos besoins, vous devriez chercher le document dont vous avez besoin. Sur notre site, vous pouvez voir le manuel le plus populaire d’utilisation du produit Lincoln Electric POWER MIG 255 SVM144-B.

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Le manuel d’utilisation, également appelé le mode d’emploi, ou tout simplement le manuel, est un document technique destiné à aider à utiliser Lincoln Electric POWER MIG 255 SVM144-B par les utilisateurs. Des manuels sont généralement écrits par un rédacteur technique, mais dans un langage accessible à tous les utilisateurs Lincoln Electric POWER MIG 255 SVM144-B.

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3. Conseils sur la façon d'utiliser les fonctions de base de l’appareil Lincoln Electric POWER MIG 255 SVM144-B - qui devraient nous aider dans les premières étapes lors de l'utilisation Lincoln Electric POWER MIG 255 SVM144-B
4. Troubleshooting - séquence systématique des activités qui nous aideront à diagnostiquer et ensuite résoudre les principaux problèmes de Lincoln Electric POWER MIG 255 SVM144-B
5. FAQ - questions fréquemment posées
6. Détails du contact Informations sur l'endroit où chercher le contact avec le fabricant / service Lincoln Electric POWER MIG 255 SVM144-B dans un pays donné, si le problème ne peut être résolu par nous-mêmes.

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